Self priming spackling compound

ABSTRACT

A self-priming spackling compound includes between about 35% by weight and about 65% by weight acrylic latex resin, between about 20% by weight and about 50% by weight filler material, and between about 1% by weight and about 20% by weight water. In certain aspects, the latex resin may have an average latex particle size of less than about 0.18 microns, a minimum film formation temperature of less than about 15 degrees Celsius, and/or a glass transition temperature (Tg) of less than about 25 degrees Celsius. To further enhance the self-priming performance of the spackling compound, the formulation may further comprise a colorant such as titanium dioxide.

BACKGROUND

The present invention relates generally to materials such as pastes orputties, often referred to as wall repair or spackling compounds, thatare used to fill and repair holes, cracks and other minor surfacedefects or imperfections in wood, drywall and/or plaster.

Interior walls of homes and buildings are often constructed using gypsumwallboard panels (sometimes referred to as drywall). When cavities,recesses, holes, etc., are present (due to imperfections or damage) itis common to use spackling compound (also referred to as wall repaircompound) to fill such cavities. Conventional spackling compounds ofteninclude one or more inorganic fillers, one or more polymeric resinbinders, and various thickeners and other additives. Lightweightspackling compounds have been developed which often contain, among otherinorganic fillers, relatively low density fillers such as glass bubbles,hollow silica, or expanded perlite. After spackling compound is appliedto a wall, the water evaporates over a period of time resulting in theformation of a dried, hardened material which can be sanded, painted,etc.

Spackling compounds are known in the prior art. U.S. Pat. No.6,531,528(Kurp), for example, discloses a ready to use patch repair product thatincludes a color change indicator. After the product has dried the colorchanges to signal that, if desired, the worker can perform otheroperations such as painting, sanding, etc on the surface. U.S. Pat. No.7,790,796 (Foster, et. al.) discloses a spackling compound that is easyto apply smoothly, can be applied in thicker layers than known spacklingwithout cracking upon drying, and can be modified after drying withoutpitting, flaking, or crumbling, particularly at the edges of the appliedspackling patch.

SUMMARY

Because spackling compound is typically more porous than the surroundingsurface to which it is applied, in order to achieve a uniform surfacethat matches the original surface, spackling compound must be primed andsealed before it is painted. If left unprimed, spackling compound willproduce dull spots that show through the paint, thereby resulting in anirregular surface where spackling compound has been used. In addition,if the wrong type of primer is used to prime the spackling compound, theprimed spackling compound may appear shiny when it is painted.

The need exists for a spackling compound that, when painted, results ina consistent and uniform appearance that closely matches a surroundingsurface without the need for priming The present invention provides aspackling compound that, when painted, results in a consistent anduniform appearance that closely matches a surrounding surface withoutthe need for priming

In one embodiment, the spackling compound comprises between about 35% byweight and about 65% by weight acrylic latex resin, between about 20% byweight and about 50% by weight filler material, and between about 1% byweight and about 20% by weight water. In one aspect, the latex resin mayhave an average latex particle size of less than about 0.15, 0.16, 0.17or 0.18 microns.

In another aspect, the spackling compound may include a resin having aminimum film formation temperature of less than about 15 degreesCelsius. In another aspect, the spackling compound may include a resinhaving a glass transition temperature (Tg) of less than about 25 degreesCelsius.

In another embodiment, the spackling compound may include at least onecolorant. In another embodiment the spackling compound containssufficient colorant so that the dried spackling compound passes the 6mil hide test set forth in the specification. In a more specificembodiment, the spackling compound may comprise between about 2%, atleast about 4%, at least about 6% or at least about 8% by weightcolorant, and no greater than about 20%, 18%, 16% or 14% by weightcolorant. In specific embodiments, the colorant may comprise titaniumdioxide, carbon black, or mixtures thereof. In an even more specificembodiment, the spackling compound may include less than about 0.02percent by weight carbon black.

In another aspect, the spackling compound may comprise a coalescing aid.In a specific embodiment, the coalescing aid may comprisetrimethylpentanediol monoisobutyrate. In another embodiment, thecoalescing aid may comprise less than about 1% by weight propyleneglycol.

In another embodiment, the spackling compound may comprise a dispersingagent. In a specific embodiment, the dispersing agent may comprise lessthan about 1 percent by weight of a sodium salt of polymeric carboxylicacid.

In another embodiment, the spackling compound may include a lubricant.In a more specific embodiment, the lubricant may comprise less thanabout 1% by weight hydroxy ethyl cellulose.

In another embodiment, the spackling compound may include a fillercomprising a bimodal distribution of particles. The bimodal distributionof particles may comprise at least one of glass bubbles and ceramicmicrospheres. In another embodiment, the filler may be substantiallyfree of mined organic filler materials.

The spackling compound may optionally include a preservative/fungicide,or a bactericide. In more specific embodiment the bactericide maycomprise 4,4-dimethyloxazolidine.

In certain embodiments, the dried spackling compound may have an average85 degree gloss retention index of at least about 0.3, at least about0.4, at least about 0.5, or at least about 0.6 when tested according tothe test set forth in the specification.

In a specific embodiment, the present invention provides a spacklingcompound including between about 45% by weight and about 60% by weightacrylic latex resin, between about 25% by weight and about 45% by weightfiller material, between about 5% by weight and about 15% by weighttitanium dioxide, and between about 1% by weight and about 15% by weightwater, wherein the latex resin has an average latex particle size ofless than about 0.18 microns, a minimum film formation temperature ofless than about 15 degrees Celsius, and a glass transition temperature(Tg) of less than about 25 degrees Celsius. In an even more specificembodiment, the dried spackling compound may have an average 85 degreegloss retention index of at least about 0.6 when tested according to thetest set forth in the specification.

An advantage of certain embodiments of the spackling compound accordingto the present disclosure is that, when painted, it blends in generallyuniformly and closely matches the appearance of a painted surroundingsurface to which it is applied. That is, the spackling compound behavesas though it has been primed even though it has not been primed. Inaddition, the spackling compound has properties such as hardness,workability, gloss retention, paint anchorage, and adhesion that aresimilar to those of conventional spackling compounds.

DETAILED DESCRIPTION

A spackling compound according to the present disclosure generallyincludes a resin, filler material and water. Other optional ingredientsmay be included in various other embodiments. In one embodiment, theresin is an acrylic resin and, more specifically, a latex acrylic resin.In a more specific embodiment, the spackling compound includes betweenabout 35% by weight and about 65% by weight latex acrylic resin, betweenabout 20% by weight and about 50% by weight filler material, and betweenabout 1% by weight and about 20% by weight water. All percentages byweight disclosed herein are based on the total as-formulated weight ofthe spackling compound (i.e., including water), unless otherwise noted.The resin, filler, and optional ingredients are each described ingreater detail below.

The self-priming spackling compound disclosed herein comprises at leastone resin binder. Suitable binders are often supplied as an aqueouslatex emulsion (comprising, for example, between 40-60 percent solids ofpolymeric resin binder, in water). Resins potentially suitable forbinders in the present spackling compound include, for example, acryliclatex emulsion resins. In various embodiments, the latex emulsion resinscan comprise at least about 20 percent, 30 percent, or 40 percent, byweight, of the spackling compound.

In accordance with one aspect of the spackling compound, it has beenfound that some resins, when used in spackling compound formulations,produce spackling compounds that—upon painting of the wall containingthe dried spackling compound—produce a better match with a paintedsurface surrounding the patched region without the need to be primed.That is, some resins result in spackling compounds that act more as ifthey have been primed when dry than others resins, thereby producing aspackling that blends in more naturally and inconspicuously with thesurrounding un-repaired substrate when painted.

More specifically, it has been found spackling compounds containingacrylic latex resins having latex particles below a certain size resultin dried spackling compound that do not need to be primed. That is, thedried spackling compound behaves more like it has been primed, wherebyit blends in more seamlessly with the surrounding surface that does notinclude the spackling compound. While not wishing to be bound by theory,it is believed that smaller latex particles allow the resin to form atighter film when the spackling compound dries, and the tighter filmresults in a spackling compound that behaves more like it has beenprimed. In specific embodiments, the resin may have an average latexparticle size of less than about 0.18 microns, less than about 0.16microns, less than about 0.14 microns, or less than about 0.12 microns.

It has also been found that resins having a glass transition temperature(T_(g)) below a certain temperature produce spackling compounds havingmore desirable primer-like properties when dried. That is, when resinshaving a Tg below a certain temperature are used in the spacklingcompound, the dried spackling compound will perform as though it hasbeen primed. As a result, the dried spackling compound when painted willclosely match the appearance of a surrounding painted surface. In someembodiments, desirable resins will have a glass transition temperatureof less than about 25° C., less than about 20° C., or less than about15° C. The term “glass transition temperature” is a term well known inthe art and generally relates to a softening temperature indicative ofthe onset of long range translational motion of polymer molecules.

It has also been found that spackling compounds including resin bindershaving a minimum film formation temperature below a certain temperaturehave more desirable primer-like properties. In some embodiments,desirable resins will have a minimum film formation temperature asdetermined according to ASTM Method D 2354-10 of less than about 18° C.,less than about 15° C., or less than about 12° C.

Specific resins suitable for use in the spackling compound include theacrylic latex emulsion binder available (as a 43.5 percent solids latexemulsion) from Arkema Coating Resins of Cary, N.C., under the tradedesignation ENCOR 627, or the acrylic latex emulsion binder available(as a 50 percent solids latex emulsion) from Arkema Coating Resins ofCary, N.C., under the trade designation ENCOR 631. The ENCOR 627 acryliclatex binder has a particle size of 0.10 microns, a minimum filmingtemperature of 9° C., and a glass transition temperature of 15° C. TheENCOR 631 acrylic latex binder has a particle size ranging from0.10-0.15 microns, a minimum filming temperature of 0° C., and a glasstransition temperature (onset) of less than 4° C.

The spackling compound includes filler. The filler may be, for example,a filler system that comprises one or more inorganic fillers. In variousembodiments, the inorganic filler system comprises at least about 15%,20%, or 25%, by weight, of the spackling compound (as previously noted,this and all other percentages by weight disclosed herein are based onthe total as-formulated weight of the spackling compound (i.e.,including water), unless otherwise noted). In further embodiments, theinorganic filler system comprises at most about 45%, 55%, or 65% byweight, of the weight of the spackling compound as formulated.

Suitable filler materials include natural inorganic materials such ascalcite, witherite, rutile, anatase, ilmenite, mica, sericite, perlite,talc, limestone, silica, barite, gypsum, calcined gypsum, kaolinite,montmorillonite, attapulgite, illite, saponite, hectorite, beidellite,stevensite, sepiolite, bentonite, pyrophyllite, diatomaceous earth, andthe like, and such as synthetic inorganic fillers such as so-calledglass bubbles (such as those available from 3M Company of St. Paul,Minn., under the trade designation 3M Glass Bubbles), ceramicmicrospheres (such as those available from 3M Company under the tradedesignation 3M Ceramic Microspheres), synthetic clays (e.g., syntheticsilicate clays such as those available under the trade designationLaponite from Southern Clay Products, Gonzales, Tex.), precipitatedsilica, fumed silica, vitreous silica, synthetic titanium dioxide (asmade, for example, by the sulfate process or the chloride process),synthetic (precipitated) calcium carbonate (as made, for example, bypassing carbon dioxide through a solution of calcium hydroxide), and thelike

In certain embodiments, the filler material comprises a bimodal particlesize mixture of larger filler particles and smaller filler particles. Invarious specific embodiments, the filler material comprises a bimodalparticle size mixture of filler particles comprising a particle sizeratio of larger particle size filler to smaller particle size filler (asobtained by ratioing the median particle size of the two fillerpopulations) of at least about 5:1, 10:1 or 15:1. In various specificembodiments, the particle size ratio is at most about 40:1, 30:1, or20:1.

In various embodiments, the larger particle size filler particlescomprise a median particle size of at least about 15, 30 or 40 microns,and of at most about 80, 65 or 55 microns. In various embodiments, thesmaller particle size synthetic inorganic filler particles comprise amedian particle size of at least about 1, 2, or 3 microns, and of atmost about 15, 10 or 5 microns.

In a specific embodiment, the synthetic inorganic fillers are comprisedof substantially spherical particles. In this context, substantiallyspherical denotes that a substantial majority of the particles arespherical except for such occasional deviations, deformities, etc. asare known to those of skill in the art to be occasionally encountered inthe manufacturing processes used to produce the particles (for example,somewhat misshapen particles may be occasionally produced, two or moreparticles may agglomerate or adhere to each other, and so on).

Suitable substantially spherical synthetic inorganic fillers as definedherein include so-called glass bubbles (such as those available from 3MCompany of St. Paul, Minn., under the trade designation 3M GlassBubbles), and ceramic microspheres (such as those available from 3MCompany under the trade designation 3M Ceramic Microspheres). Such glassbubbles can be synthesized, for example, by a process as described inU.S. Pat. Nos. 3,365,315 and 4,391,646. Such ceramic microspheres can besynthesized, for example, by sol-gel processes, as described for examplein U.S. Pat. Nos. 3,709,706 and 4,166,147. Other methods potentiallyuseful for making ceramic particles and/or microspheres are describedin, for example, U.S. Pat. No. 6,027,799.

In particular embodiments, the larger particle size synthetic inorganicfiller comprises glass bubbles and the smaller particle size syntheticinorganic filler comprises ceramic microspheres. In various embodiments,the glass bubbles comprise a median particle size of at least about 15,30 or 40 microns, and of at most about 80, 65 or 55 microns. In variousembodiments, the ceramic microspheres comprise a median particle size ofat least about 1, 2, or 3 microns, and of at most about 15, 10 or 5microns.

It has been found that the use of such substantially spherical fillersas described above, and in particular the use of a bimodal mixture ofsuch fillers, can help provide a spackling compound that spreads easilyand yet does not sag, run or slump to an excessive degree when appliedto a vertical surface.

To enhance the ability of the spackling compound to “hide”, thespackling compound may also include one or more colorants. One suitablecolorant is, for example, titanium dioxide. While not wishing to bebound by theory, it is believed that titanium dioxide reflects light andthereby effectively hides differences in the substrate color/appearancewhen added to the spackling compound formulation. In a specificembodiment, the amount of titanium dioxide may range from at least about3%, 5%, or 7% by weight, to no greater than 20%, 17%, or 15% by weight.Another suitable colorant is carbon black. Specific colorants suitablefor use in the spackling compound include TI-PURE R700 titanium dioxideavailable from DuPont Chemicals, Wilmington, Del., and MONARCH 120carbon black available from Cabot Corporation, Boston, Mass.

To enhance the film forming properties of the resin, the spacklingcompound may include a coalescing aid, which may also be referred to asa coalescing aid. While not wishing to be bound by theory, it isbelieved that the coalescing aid serves to soften the latex particles sothe individual particles combine to form a continuous film. In aspecific embodiment, the coalescing aid comprises less than about 1% byweight of the spackling compound formulation. Suitable coalescing aidsinclude COASOL coalescing aid available from Dow Haltermann CustomProcessing, Middlesbrough, UK, and TEXANOL ester alcohol available fromEastman Chemical Kingsport, Tenn.

In other embodiments, the coalescing aid may include hydrocarbonmolecules comprising exactly one hydroxyl group and further comprisingan ether linkage. In one embodiment, the coalescing aid comprises one ormore of the compounds generally known in the art as glycol ethers andcomprising a linear hydrocarbon chain with exactly one or exactly twoether groups in the chain, and bearing a single hydroxyl group. Thehydroxyl group may for example be attached to a terminal carbon of thechain, or attached to a carbon adjacent to a terminal carbon of thechain, or attached to some other carbon of the molecule. The linearchain may also comprise one or more methyl groups or other alkyl groupsattached to the carbons of the chain.

Such glycol ether coalescing aids typically comprise a relatively lowmolecular weight (e.g., from about 90 g/mole to about 250 g/mole); aretypically liquid at room temperature (e.g., 22° C.); and, whiletypically being partially or completely miscible with water, do not actto substantially increase the viscosity of water when added to water.

As such, these glycol ether coalescing aids are distinguished fromorganic polymeric thickeners such as the above-described relatively highmolecular weight polyhydroxy materials that comprise multiple hydroxylgroups. As such, they are also distinguished from organic polymericthickeners such as poly(ethylene oxide) and/or polyethylene glycol andderivatives thereof, which, although possibly not possessing hydroxyls,possess multiple (e.g., greater than three) ether linkages which renderthe molecules relatively hydrophilic and serve to make them function ina well known capacity as aqueous viscosity-increasing agents.

Thus in summary, the glycol ether coalescing aids disclosed herein maybe distinguished from conventional thickeners based on their chemicalformula and/or their chemical structure; and/or, when used in a wallrepair compound, by the apparent viscosity-lowering effect of thecoalescing aids, and/or by the absence of the relatively high shrinkupon drying which is often associated with conventional thickeners.

The glycol ether coalescing aids disclosed herein may also bedistinguished from relatively small, low molecular weight (e.g., lessthan about 500 g/mole) molecules that have multiple hydroxyls. Such lowmolecular weight polyhydroxy molecules have been found by the inventorsnot to have the advantageous effects of the glycol ether coalescingaids. For example, a wall repair formulation comprising glycerol (MW of92 g/mole, with three hydroxyls) was found by the inventors to exhibit amuch tackier consistency which lacked certain advantageous properties ofthe compositions described above. Such low molecular weight polyhydroxymolecules are sometimes found in wall repair compounds (for example, asmentioned in U.S. Pat. No. 4,629,751 as being useable to inhibitgelation of certain wall repair compositions). Thus, in certainembodiments, the wall repair compounds disclosed herein comprise lessthan 0.1, 0.05, or 0.02 percent, by weight, of low molecular weightpolyhydroxy molecules.

In other embodiments the spackling compound further comprises adispersing agent. The dispersing agent may comprise, for example, asodium salt of polymeric carboxylic acid. In a specific embodiment, thedispersing agent comprises less than about 1% by weight of the spacklingcompound formulation. A suitable dispersing agent is available from Rohmand Haas Company, Philadelphia, Pa. under the tradename TAMOL 850.

The spackling compound may also include a thickener (also referred to aslubricants, gelling agents, bodying agents, water retention agents,etc.). Suitable thickeners include, for example, polysaccharides andderivatives thereof, for example, the well known cellulose ethers (e.g.,methyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, hydroxyethyl methyl cellulose,hydroxyethyl hydroxypropyl cellulose, ethylhydroxyethyl cellulose, andsodium carboxymethyl cellulose). Such thickeners can also include forexample polyethylene glycol, polyethylene oxide (and/or polyethyleneoxide/polypropylene oxide copolymers), polyvinyl alcohol, polymers orcopolymers of ethylenically unsaturated carboxylic acids and theirderivatives, such as acrylic acid and acrylamide, guar gum, xanthan gum,alginates, tragacanth gum, pectin, amylopectin, dextran, polydextrose,and the like. In a specific embodiment, the lubricant comprises lessthan about 1% by weight of the spackling compound formulation. Incertain embodiments, a desirable lubricant is hydroxyethyl cellulose.

Certain natural or synthetic inorganic fillers (for example, clays suchas attapulgite, bentonite, montmorillonite, illite, kaolinite,sepiolite, the synthetic clay available under the trade designationLaponite from Southern Clay Products, etc.), are known to exhibit athickening (e.g., viscosity-increasing) effect when dispersed in water.Such materials (particularly those that absorb water and/or swell uponexposure to water) have commonly been used as thickeners in spacklingcompounds (they are also occasionally referred to in the art as rheologymodifiers, non-leveling agents, etc.), and are known in the art tocontribute to shrinkage upon drying (as discussed, for example, in U.S.Pat. No. 4,824,879). Thus, in certain embodiments, the spacklingcompounds disclosed herein comprise less than 0.1, 0.05, or 0.02percent, by weight, of (natural or synthetic) inorganic thickeningfiller clay. In a particular embodiment, the spackling compounds mayinclude less than about 0.1 percent by weight of inorganic thickeningfiller clay, and further comprise less than about 0.1 percent by weightof organic polymeric thickener.

In addition to the components described above, other components may beadded to the spackling compound. These additional ingredients mayinclude, for example, water, which may be added at the end of theproduction process, for final adjustment of e.g., viscosity. Thus, incertain embodiments, water (in addition to the water present in theaqueous latex binder emulsion) may be added to the formulation. Otheradditives that may be present include preservatives which may haveadvantageous effects on the spackling compound during storage, and mayalso serve to minimize the degree to which mold or fungus may grow onthe dried spackling compound. Thus in certain embodiments, the spacklingcompound may include at least about 0.1 percent, 0.2 percent, or 0.3percent by weight of a preservative or preservatives. In furtherembodiments, the spackling compound may include no greater than at mostabout 1.0 percent, 0.8 percent, or 0.6 percent by weight of apreservative or preservatives. Suitable preservatives include, forexample, those available under the designation Mergal 192 and PolyphaseP20T, from Troy Corporation of Florham Park, N.J.

The spackling compound may also include dust reducing additives which insome circumstances may serve to further reduce the quantity of airbornedust particles generated when sanding the dried, hardened spacklingcompound. Exemplary dust reducing additives include, for example, oils(such as mineral oils, vegetable oils, and animal oils), waxes(including natural and synthetic waxes), and the like. Suitable dustreducing additives may be chosen, for example, from those discussed inU.S. Pat. No. 6,358,309, the entire contends of which are hereinincorporated by reference for this purpose.

Other components may also be added to the spackling compound formulationfor various purposes, including but not limited to, antifreezeadditives, surfactants, defoamers, plasticizers (e.g., for the polymericbinder used), reinforcing fibers, and so on. Such additives may beincluded as long as they do not significantly detract from otherdesirable properties of the spackling compound or unduly interfere withthe use of the formulation as a spackling compound.

EXAMPLES

In order that the invention described herein can be more fullyunderstood, the following examples are set forth. It should beunderstood that these examples are for illustrative purposes only, andare not to be construed as limiting this invention in any manner.

Test Methods

Hardness

An approximately 6 inch long by 1.5 inch wide by 0.25 inch deep mass ofspackle was cast using a form of the same dimensions onto primed (PROMARWhite Interior Latex Primer B28 W 8200, available from Sherwin-WilliamsCompany, Cleveland, Ohio) drywall board (GOLD BOND Gypsum Board,available from National Gypsum, Charlotte, N.C.). To ensure that thespackle surface was level, a flexible putty knife was run over the topof the form. The form was removed and the spackle was allowed dry atambient conditions for 24 hours.

After 24 hours, the surface of the spackle was lightly sanded using afine grade sanding sponge to ensure that it was level (3M Pro Grade FineSanding Sponge, available from 3M Company, Maplewood, Minn.). Thespackle surface was then wiped with a damp cloth to remove any dust anddebris.

A Shore Durometer (Type OO available from Instron Company, Norwood,Mass.) was used to obtain the Shore hardness values. The durometer wasplaced across the width of the spackle sample and an initial reading wasquickly recorded. After 60 seconds a second reading was recorded. Thedata reported in the Tables is an average of three readings taken on thesame sample.

Paint Gloss Retention Index

An approximately 6 inch long by 1.5 inch wide by 0.25 inch deep mass ofspackle was cast using a form of the same dimensions onto primed (PROMARWhite Interior Latex Primer B28 W 8200, available from Sherwin-WilliamsCompany, Cleveland, Ohio) drywall board (GOLD BOND Gypsum Board,available from National Gypsum, Charlotte, N.C.). To ensure that thespackle surface was level, a flexible putty knife was run over the topof the form. The form was removed and the spackle was allowed dry atambient conditions for 24 hours.

After 24 hours, the surface of the spackle was lightly sanded using afine grade sanding sponge to ensure that it was level (3M Pro Grade FineSanding Sponge, available from 3M Company, Maplewood, Minn.). Thespackle surface was then wiped with a damp cloth to remove any dust anddebris.

A thin, complete coating of paint was applied to the spackle surfaceusing a paint brush (Wooster 4212 LINDBECK Neat Double Angle Sash PaintBrush, available from The Wooster Brush Company, Wooster, Ohio) and awaterborne interior paint (AURA waterborne interior paint, eggshellfinish, blazing orange, available from Hirshfield's, Woodbury, Minn.).The paint brush was passed back and forth across the spackle surface atleast two times. The paint coating was allowed to dry at ambientconditions for 24 hours. A small section of the primed drywall board wasalso be painted in order to obtain gloss readings on primed drywallboard wallboard (as a control) for a Paint Gloss Retention Indexcalculation.

After drying for 24 hours, the gloss was measured using a handheld glossmeter (micro-TRI-gloss, Cat. No. 4520, available from BYK Gardner Inc.Silver Spring, Md.) and the results recorded. The Gloss Retention Indexwas calculated by comparing the gloss reading of a painted spacklesample at 85 degree (Deg) and dividing it by the gloss reading of thepainted, primed drywall board at 85 Deg. The data reported in the Tablesare an average of three readings taken on the same sample.

Gloss Retention Index=85 Deg Gloss Reading of painted spackle sample/85Deg Gloss Reading of painted, primed drywall board

Paint Anchorage

An approximately 6 inch long by 1.5 inch wide by 0.25 inch deep mass ofspackle was cast using a form of the same dimensions onto primed (PROMARWhite Interior Latex Primer B28 W 8200, available from Sherwin-WilliamsCompany, Cleveland, Ohio) drywall board (GOLD BOND Gypsum Board,available from National Gypsum, Charlotte, N.C.). To ensure that thespackle surface was level a flexible putty knife was run over the top ofthe form. The form was removed and the spackle was allowed dry atambient conditions for 24 hours.

After 24 hours, the surface of the spackle was lightly sanded using afine grade sanding sponge to ensure that it was level (3M Pro Grade FineSanding Sponge, available from 3M Company, Maplewood, Minn.). Thespackle surface was then wiped with a damp cloth to remove any dust anddebris.

A thin, complete coating of paint was applied to the spackle surfaceusing a paint brush (Wooster 4212 LINDBECK Neat Double Angle Sash PaintBrush, available from The Wooster Brush Company, Wooster, Ohio) and awaterborne interior paint (AURA waterborne interior paint, eggshellfinish, blazing orange, available from Hirshfield's, Woodbury, Minn.).The paint brush was passed back and forth across the spackle surface atleast two times. The paint coating was allowed to dry (at ambientconditions?) for 24 hours. After drying for 24 hours, a 1 inch widestrip of suitable masking tape (SCOTCH BLUE #2093 Advanced Multi-SurfacePainter's Tape with EDGE-LOCK, available from 3M Company, Maplewood,Minn.) was applied to the spackle surface and was and pressed downfirmly with thumb pressure. The tape was allowed to dwell on the spacklesurface for 24 hours. Then the tape was pulled off of the spacklesurface in a direction parallel to the surface (180° peel) at anapproximate rate of 12 inches per minute. If any paint was removed withthe tape, the sample was classified as “Fail”. If no paint was removedby the tape, the sample was classified as “Pass”.

Hiding Power Comparison

An approximately 6 inch long by 1.5 inch wide by 6 mil deep mass ofspackle was cast using a form of the same dimensions onto a LenetaSpreading Rate Chart (Form 13H Spreading Rate Chart, patterned withblack and white stripes, available from Leneta Company, Mahwah, N.J.). Aflexible putty knife was run over the top of the form to ensure that thespackle surface was level. The form was removed and the spackle wasallowed to dry at ambient conditions for 24 hours.

After the spackle had dried for 24 hours, the mass of spackle wasinspected to determine if there was any show through (i.e., could blackcolor been seen through the spackle layer). If show through wasobserved, this was recorded as “Fail”. If there was no show through,this was recorded as “Pass”.

EXAMPLES Example 1

A batch of wall repair compound was synthesized by the following generalmethods. The following equipment was provided: a high shear mixerequipped with a Cowles Blade, and a low shear (Hobart) mixer. ENCORLatex 627 (100% acrylic latex) was obtained from Arkema Coating Resins.The ENCOR 627 acrylic latex binder has a particle size of 0.10 microns,a minimum film forming temperature of 9° C., and a glass transitiontemperature of 15° C. K-20 Glass bubbles were obtained from 3M Company.W210 Ceramic Microspheres were obtained from 3M Company. Titaniumdioxide (TI-PURE R700) was obtained from DuPont Chemicals, Wilmington,Del. POLYPHASE P20T and MERGAL 192 biocides were obtained from TroyCorporation. Propylene glycol butyl ether (CAS Number 5131-66-8) wasobtained from Sigma-Aldrich, St. Louis, Mo., under the product number484415 (and is believed to be substantially equivalent to the productobtainable from Dow Chemical under the trade designation DOWANOL PnB).DYNOL 604 antifoam is available from Air Products. MONARCH 120 carbonblack is available from the Cabot Corporation. The particle size ofMONARCH 120 is about 60 nm and the size of the dispersed aggregate is150-200 nm. MONARCH 120 has a tint strength of 55 tint units, asmeasured by ASTM D3265-11.

The ENCOR 627 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The DYNOL 604, POLYPHASE P20T, MERGAL 192,propylene glycol butyl ether, and MONARCH 120 were then addedsequentially, while stirring on low speed. Following this, the W210ceramic microspheres were slowly added with the mixer initially set onlow speed. As the viscosity of the mixture built upon addition of theceramic microspheres, the mixer speed was increased. After addition wascomplete, mixing of this pre-mix was continued for approximately 5minutes. The premix was then used without delay in the following step:The glass bubble filler was added to the mixing bowl of the low shearmixer. The premix was then added to the mixer by aid of a rubber spatulaand the mixer was covered with a plastic or aluminum film to contain thevery low density glass bubbles that tend to be stirred out of the bowlwithout a physical means to contain them. After providing thiscontainment, the mixer was started on low speed very briefly multipletimes until virtually all the glass bubbles were wet with the premixmixture. At that point the plastic or aluminum film could be removedfrom the bowl. At this point the mixer speed was increased to medium forapproximately two minutes, then to high for approximately one minute.The mixer was then stopped and the batch was inspected. Water was addedas needed to provide the desired consistency of the product. A skilledoperator can determine the amount of water to add while mixing at highspeed by auscultation; if the viscosity is the correct range, themixture will make a distinctive low pitched sound as air begins to beentrained in the mixture. The mixture was then transferred to a plasticbucket with a lid, for storage.

All components listed in Table 1 for Example 1 are in weight percent, ofthe wall repair compound as formulated. (ENCOR 627 is an aqueousemulsion comprising 50 percent total solids). The batch size wasapproximately 2.0 kilograms (kg). It should be understood that thepercentages reported for this and the other Examples herein reflect theaccuracy and tolerances of the apparatus and measurements used.

TABLE 1 Component Weight Percent ENCOR 627 Binder Emulsion 47.05 K-20Glass Bubbles 21.30 Ceramic Microspheres 13.09 Titanium Dioxide 11.61Propylene Glycol Butyl Ether 0.20 POLYPHASE P20T 0.35 MERGAL 192 0.09Antifoam 0.002 Carbon Black 0.006 Water to adjust 6.29

Example 2

A batch of wall repair compound was synthesized by the following generalmethods. The following equipment was provided: a high shear mixerequipped with a Cowles Blade, and a low shear (Hobart) mixer. ENCORLatex 631 (binder emulsion) was obtained from Arkema Coating Resins. TheENCOR 631 acrylic latex binder has a particle size ranging from0.10-0.15 microns, a minimum film forming temperature of 0 ° C., and aglass transition temperature (onset) of less than 4° C. The latex binderwas provided in an amount small than the amount provided in Example 1.

K-20 Glass bubbles were obtained from 3M Company. W210 CeramicMicrospheres were obtained from 3M Company. POLYPHASE P20T and MERGAL192 biocides were obtained from Troy Corporation. Propylene glycol butylether (CAS Number 5131-66-8) was obtained from Sigma-Aldrich, St. Louis,Mo., under the product number 484415 (and is believed to besubstantially equivalent to the product obtainable from Dow Chemicalunder the trade designation DOWANOL PnB).

The ENCOR 631 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The POLYPHASE P20T, MERGAL 192, and propyleneglycol butyl ether were then added sequentially, while stirring on lowspeed. Following this, the W210 ceramic microspheres were slowly addedwith the mixer initially set on low speed. As the viscosity of themixture built upon addition of the ceramic microspheres, the mixer speedwas increased. After addition was complete, mixing of this pre-mix wascontinued for approximately 5 minutes. The premix was then used withoutdelay in the following step: The glass bubble filler was added to themixing bowl of the low shear mixer. The premix was then added to themixer by aid of a rubber spatula and the mixer was covered with aplastic or aluminum film to contain the very low density glass bubblesthat tend to be stirred out of the bowl without a physical means tocontain them. After providing this containment, the mixer was started onlow speed very briefly multiple times until virtually all the glassbubbles were wet with the premix mixture. At that point the plastic oraluminum film could be removed from the bowl. At this point the mixerspeed was increased to medium for approximately two minutes, then tohigh for approximately one minute. The mixer was then stopped and thebatch was inspected. Water was added as needed to provide the desiredconsistency of the product. A skilled operator can determine the amountof water to add while mixing at high speed by auscultation; if theviscosity is the correct range, the mixture will make a distinctive lowpitched sound as air begins to be entrained in the mixture. The mixturewas then transferred to a plastic bucket with a lid, for storage.

All components listed in Table 2 for Example 2 are in weight percent, ofthe wall repair compound as formulated. (ENCOR 631 is an aqueousemulsion comprising 50 percent total solids). The batch size wasapproximately 400 grams (g).

TABLE 2 Component Weight Percent ENCOR 631 Binder Emulsion 38.19 K-20Glass Bubbles 27.10 Ceramic Microspheres 16.65 Propylene Glycol ButylEther 0.25 POLYPHASE P20T 0.44 MERGAL 192 0.11 Water to adjust 17.25

Example 3

A batch of wall repair compound was synthesized by the following generalmethods. The following equipment was provided: a high shear mixerequipped with a Cowles Blade, and a low shear (Hobart) mixer. ENCORLatex 631 (binder emulsion) was obtained from Arkema Coating Resins. TheENCOR 631 acrylic latex binder has a particle size ranging from0.10-0.15 microns, a minimum film forming temperature of 0 ° C., and aglass transition temperature (onset) of less than 4° C. The latex binderwas provided in a quantity greater than the amount provided in Example1.

K-20 Glass bubbles were obtained from 3M Company. W210 CeramicMicrospheres were obtained from 3M Company. POLYPHASE P20T and MERGAL192 biocides were obtained from Troy Corporation. Propylene glycol butylether (CAS Number 5131-66-8) was obtained from Sigma-Aldrich, St. Louis,Mo., under the product number 484415 (and is believed to besubstantially equivalent to the product obtainable from Dow Chemicalunder the trade designation DOWANOL PnB).

The ENCOR 631 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The POLYPHASE P20T, MERGAL 192, and propyleneglycol butyl ether were then added sequentially, while stirring on lowspeed. Following this, the W210 ceramic microspheres were slowly addedwith the mixer initially set on low speed. As the viscosity of themixture built upon addition of the ceramic microspheres, the mixer speedwas increased. After addition was complete, mixing of this pre-mix wascontinued for approximately 5 minutes. The premix was then used withoutdelay in the following step: The glass bubble filler was added to themixing bowl of the low shear mixer. The premix was then added to themixer by aid of a rubber spatula and the mixer was covered with aplastic or aluminum film to contain the very low density glass bubblesthat tend to be stirred out of the bowl without a physical means tocontain them. After providing this containment, the mixer was started onlow speed very briefly multiple times until virtually all the glassbubbles were wet with the premix mixture. At that point the plastic oraluminum film could be removed from the bowl. At this point the mixerspeed was increased to medium for approximately two minutes, then tohigh for approximately one minute. The mixer was then stopped and thebatch was inspected. Water was added as needed to provide the desiredconsistency of the product. A skilled operator can determine the amountof water to add while mixing at high speed by auscultation; if theviscosity is the correct range, the mixture will make a distinctive lowpitched sound as air begins to be entrained in the mixture. The mixturewas then transferred to a plastic bucket with a lid, for storage.

All components listed in Table 3 for Example 3 are in weight percent, ofthe wall repair compound as formulated. (ENCOR 631 is an aqueousemulsion comprising 50 percent total solids). The batch size wasapproximately 450 g.

TABLE 3 Component Weight Percent ENCOR 631 Binder Emulsion 54.87 K-20Glass Bubbles 24.84 Ceramic Microspheres 15.26 Propylene Glycol ButylEther 0.23 POLYPHASE P20T 0.41 MERGAL 192 0.10 Water to adjust 4.29

Example 4

A batch of wall repair compound was synthesized using a different binderemulsion than in Examples 1-3 by the following general methods. Thefollowing equipment was provided: a high shear mixer equipped with aCowles Blade, and a low shear (Hobart) mixer. ENCOR Latex 631 (binderemulsion) was obtained from Arkema Coating Resins. The ENCOR 631 acryliclatex binder has a particle size ranging from 0.10-0.15 microns, aminimum film forming temperature of 0° C., and a glass transitiontemperature (onset) of less than 4° C. K-20 Glass bubbles were obtainedfrom 3M Company. W210 Ceramic Microspheres were obtained from 3MCompany. Titanium dioxide (TI-PURE R700) was obtained from DuPontChemicals, Wilmington, Del. POLYPHASE P20T and MERGAL 192 biocides wereobtained from Troy Corporation. Propylene glycol butyl ether (CAS Number5131-66-8) was obtained from Sigma-Aldrich, St. Louis, Mo., under theproduct number 484415 (and is believed to be substantially equivalent tothe product obtainable from Dow Chemical under the trade designationDOWANOL PnB). DYNOL 604 antifoam is available from Air Products. MONARCH120 carbon black is available from the Cabot Corporation. The particlesize of MONARCH 120 is about 60 nm and the size of the dispersedaggregate is 150-200 nm. MONARCH 120 has a tint strength of 55 tintunits, as measured by ASTM D3265-11.

The ENCOR 631 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The DYNOL 604, POLYPHASE P20T, MERGAL 192, andpropylene glycol butyl ether were then added sequentially, whilestirring on low speed. Following this, the W210 ceramic microspheres,followed by titanium dioxide were slowly added with the mixer initiallyset on low speed. As the viscosity of the mixture built upon addition ofthe ceramic microspheres and titanium dioxide, the mixer speed wasincreased. After addition was complete, mixing of this pre-mix wascontinued for approximately 5 minutes. The premix was then used withoutdelay in the following step: The glass bubble filler was added to themixing bowl of the low shear mixer. The premix was then added to themixer by aid of a rubber spatula and the mixer was covered with aplastic or aluminum film to contain the very low density glass bubblesthat tend to be stirred out of the bowl without a physical means tocontain them. After providing this containment, the mixer was started onlow speed very briefly multiple times until virtually all the glassbubbles were wet with the premix mixture. At that point the plastic oraluminum film could be removed from the bowl. At this point the mixerspeed was increased to medium for approximately two minutes, then tohigh for approximately one minute. The mixer was then stopped and thebatch was inspected. Water was added as needed to provide the desiredconsistency of the product. A skilled operator can determine the amountof water to add while mixing at high speed by auscultation; if theviscosity is the correct range, the mixture will make a distinctive lowpitched sound as air begins to be entrained in the mixture. The mixturewas then transferred to a plastic bucket with a lid, for storage.

All components listed in Table 4 for Example 4 are in weight percent, ofthe wall repair compound as formulated. (ENCOR 631 is an aqueousemulsion comprising 50 percent total solids). The batch size wasapproximately 400 g.

TABLE 4 Component Weight Percent ENCOR 631 Binder Emulsion 47.38 K-20Glass Bubbles 21.45 Ceramic Microspheres 13.18 Titanium Dioxide 11.70Propylene Glycol Butyl Ether 0.20 POLYPHASE P20T 0.35 MERGAL 192 0.09Antifoam 0.002 Carbon Black 0.006 Water to adjust 5.65

Example 5

A batch of wall repair compound using 10% DOWANOL PnB was synthesized bythe following general methods. The following equipment was provided: ahigh shear mixer equipped with a Cowles Blade, and a low shear (Hobart)mixer. ENCOR Latex 627 (binder emulsion) was obtained from ArkemaCoating Resins. The ENCOR 627 acrylic latex binder has a particle sizeof 0.10 microns, a minimum film forming temperature of 9° C., and aglass transition temperature of 15° C. K-20 Glass bubbles were obtainedfrom 3M Company. K-20 Glass bubbles were obtained from 3M Company. W210Ceramic Microspheres were obtained from 3M Company. Titanium dioxide(TI-PURE R700) was obtained from DuPont Chemicals, Wilmington, Del.POLYPHASE P20T and MERGAL 192 biocides were obtained from TroyCorporation. Propylene glycol butyl ether (CAS Number 5131-66-8) wasobtained from Sigma-Aldrich, St. Louis, Mo., under the product number484415 (and is believed to be substantially equivalent to the productobtainable from Dow Chemical under the trade designation DOWANOL PnB).TEXANOL Ester Alcohol(2,2,4-Trimethyl-1,3-pentanediolmono(2-methylpropanoate)), CAS Number25265-77-4, was obtained from the Eastman Chemical Company, Kingsport,Tenn. DYNOL 604 antifoam is available from Air Products. MONARCH 120carbon black is available from the Cabot Corporation. The particle sizeof MONARCH 120 is about 60 nm and the size of the dispersed aggregate is150-200 nm. MONARCH 120 has a tint strength of 55 tint units, asmeasured by ASTM D3265-11.

The ENCOR 627 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The DYNOL 604, POLYPHASE P20T, MERGAL 192,propylene glycol butyl ether, TEXANOL and MONARCH 120 were then addedsequentially, while stirring on low speed. Following this, the W210ceramic microspheres were slowly added with the mixer initially set onlow speed. As the viscosity of the mixture built upon addition of theceramic microspheres, the mixer speed was increased. After addition wascomplete, mixing of this pre-mix was continued for approximately 5minutes. The premix was then used without delay in the following step:The glass bubble filler was added to the mixing bowl of the low shearmixer. The premix was then added to the mixer by aid of a rubber spatulaand the mixer was covered with a plastic or aluminum film to contain thevery low density glass bubbles that tend to be stirred out of the bowlwithout a physical means to contain them. After providing thiscontainment, the mixer was started on low speed very briefly multipletimes until virtually all the glass bubbles were wet with the premixmixture. At that point the plastic or aluminum film could be removedfrom the bowl. At this point the mixer speed was increased to medium forapproximately two minutes, then to high for approximately one minute.The mixer was then stopped and the batch was inspected. Water was addedas needed to provide the desired consistency of the product. A skilledoperator can determine the amount of water to add while mixing at highspeed by auscultation; if the viscosity is the correct range, themixture will make a distinctive low pitched sound as air begins to beentrained in the mixture. The mixture was then transferred to a plasticbucket with a lid, for storage.

All components listed in Table 5 for Example 5 are in weight percent, ofthe wall repair compound as formulated. (ENCOR 627 is an aqueousemulsion comprising 50 percent total solids). The batch size wasapproximately 250 g.

TABLE 5 Component Weight Percent ENCOR 627 Binder Emulsion 46.92 K-20Glass Bubbles 21.24 Ceramic Microspheres 13.05 Titanium Dioxide 11.58Propylene Glycol Butyl Ether 0.18 TEXANOL 0.02 POLYPHASE P20T 0.35MERGAL 192 0.09 Antifoam 0.002 Carbon Black 0.006 Water to adjust 6.56

Example 6

A batch of wall repair compound was synthesized using 20% DOWANOL PnB bythe following general methods. The following equipment was provided: ahigh shear mixer equipped with a Cowles Blade, and a low shear (Hobart)mixer. ENCOR Latex 627 (binder emulsion) was obtained from ArkemaCoating Resins. The ENCOR 627 acrylic latex binder has a particle sizeof 0.10 microns, a minimum film forming temperature of 9° C., and aglass transition temperature of 15° C. K-20 Glass bubbles were obtainedfrom 3M Company. K-20 Glass bubbles were obtained from 3M Company. W210Ceramic Microspheres were obtained from 3M Company. Titanium dioxide(TI-PURE R700) was obtained from DuPont Chemicals, Wilmington, Del.POLYPHASE P20T and MERGAL 192 biocides were obtained from TroyCorporation. Propylene glycol butyl ether (CAS Number 5131-66-8) wasobtained from Sigma-Aldrich, St. Louis, Mo., under the product number484415 (and is believed to be substantially equivalent to the productobtainable from Dow Chemical under the trade designation DOWANOL PnB).TEXANOL Ester Alcohol(2,2,4-Trimethyl-1,3-pentanediolmono(2-methylpropanoate)), CAS Number25265-77-4, was obtained from the Eastman Chemical Company, Kingsport,Tenn. DYNOL 604 antifoam is available from Air Products. MONARCH 120carbon black is available from the Cabot Corporation. The particle sizeof MONARCH 120 is about 60 nm and the size of the dispersed aggregate is150-200 nm. MONARCH 120 has a tint strength of 55 tint units, asmeasured by ASTM D3265-11.

The ENCOR 627 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The DYNOL 604, POLYPHASE P20T, MERGAL 192,propylene glycol butyl ether, TEXANOL and MONARCH 120 were then addedsequentially, while stirring on low speed. Following this, the W210ceramic microspheres were slowly added with the mixer initially set onlow speed. As the viscosity of the mixture built upon addition of theceramic microspheres, the mixer speed was increased. After addition wascomplete, mixing of this pre-mix was continued for approximately 5minutes. The premix was then used without delay in the following step:The glass bubble filler was added to the mixing bowl of the low shearmixer. The premix was then added to the mixer by aid of a rubber spatulaand the mixer was covered with a plastic or aluminum film to contain thevery low density glass bubbles that tend to be stirred out of the bowlwithout a physical means to contain them. After providing thiscontainment, the mixer was started on low speed very briefly multipletimes until virtually all the glass bubbles were wet with the premixmixture. At that point the plastic or aluminum film could be removedfrom the bowl. At this point the mixer speed was increased to medium forapproximately two minutes, then to high for approximately one minute.The mixer was then stopped and the batch was inspected. Water was addedas needed to provide the desired consistency of the product. A skilledoperator can determine the amount of water to add while mixing at highspeed by auscultation; if the viscosity is the correct range, themixture will make a distinctive low pitched sound as air begins to beentrained in the mixture. The mixture was then transferred to a plasticbucket with a lid, for storage.

All components listed in Table 6 for Example 6 are in weight percent, ofthe wall repair compound as formulated. (ENCOR 627 is an aqueousemulsion comprising 50 percent total solids). The batch size wasapproximately 250 g.

TABLE 6 Component Weight Percent ENCOR 627 Binder Emulsion 46.92 K-20Glass Bubbles 21.24 Ceramic Microspheres 13.05 Titanium Dioxide 11.58Propylene Glycol Butyl Ether 0.16 TEXANOL 0.04 POLYPHASE P20T 0.35MERGAL 192 0.09 Antifoam 0.002 Carbon Black 0.006 Water to adjust 6.56

Example 7

A batch of wall repair compound was synthesized using 40% DOWANOL PnB bythe following general methods. The following equipment was provided: ahigh shear mixer equipped with a Cowles Blade, and a low shear (Hobart)mixer. ENCOR Latex 627 (binder emulsion) was obtained from ArkemaCoating Resins. The ENCOR 627 acrylic latex binder has a particle sizeof 0.10 microns, a minimum film forming temperature of 9° C., and aglass transition temperature of 15° C. K-20 Glass bubbles were obtainedfrom 3M Company. K-20 Glass bubbles were obtained from 3M Company. W210Ceramic Microspheres were obtained from 3M Company. Titanium dioxide(TI-PURE R700), was obtained from DuPont Chemicals, Wilmington, Del.POLYPHASE P20T and MERGAL 192 biocides were obtained from TroyCorporation. Propylene glycol butyl ether (CAS Number 5131-66-8) wasobtained from Sigma-Aldrich, St. Louis, Mo., under the product number484415 (and is believed to be substantially equivalent to the productobtainable from Dow Chemical under the trade designation DOWANOL PnB).TEXANOL Ester Alcohol(2,2,4-Trimethyl-1,3-pentanediolmono(2-methylpropanoate)), CAS Number25265-77-4, was obtained from the Eastman Chemical Company, Kingsport,Tenn. DYNOL 604 antifoam is available from Air Products. MONARCH 120carbon black is available from the Cabot Corporation. The particle sizeof MONARCH 120 is about 60 nm and the size of the dispersed aggregate is150-200 nm. MONARCH 120 has a tint strength of 55 tint units, asmeasured by ASTM D3265-11.

The ENCOR 627 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The DYNOL 604, POLYPHASE P20T, MERGAL 192,propylene glycol butyl ether, TEXANOL and MONARCH 120 were then addedsequentially, while stirring on low speed. Following this, the W210ceramic microspheres were slowly added with the mixer initially set onlow speed. As the viscosity of the mixture built upon addition of theceramic microspheres, the mixer speed was increased. After addition wascomplete, mixing of this pre-mix was continued for approximately 5minutes. The premix was then used without delay in the following step:The glass bubble filler was added to the mixing bowl of the low shearmixer. The premix was then added to the mixer by aid of a rubber spatulaand the mixer was covered with a plastic or aluminum film to contain thevery low density glass bubbles that tend to be stirred out of the bowlwithout a physical means to contain them. After providing thiscontainment, the mixer was started on low speed very briefly multipletimes until virtually all the glass bubbles were wet with the premixmixture. At that point the plastic or aluminum film could be removedfrom the bowl. At this point the mixer speed was increased to medium forapproximately two minutes, then to high for approximately one minute.The mixer was then stopped and the batch was inspected. Water was addedas needed to provide the desired consistency of the product. A skilledoperator can determine the amount of water to add while mixing at highspeed by auscultation; if the viscosity is the correct range, themixture will make a distinctive low pitched sound as air begins to beentrained in the mixture. The mixture was then transferred to a plasticbucket with a lid, for storage.

All components listed in Table 7 for Example 7 are in weight percent, ofthe wall repair compound as formulated. (ENCOR 627 is an aqueousemulsion comprising 50 percent total solids). The batch size wasapproximately 250 g.

TABLE 7 Component Weight Percent ENCOR 627 Binder Emulsion 46.74 K-20Glass Bubbles 21.16 Ceramic Microspheres 13.00 Titanium Dioxide 11.54Propylene Glycol Butyl Ether 0.12 TEXANOL 0.08 POLYPHASE P20T 0.35MERGAL 192 0.09 Antifoam 0.002 Carbon Black 0.006 Water to adjust 6.92

Comparative Example C1

A batch of wall repair compound was synthesized by the following generalmethods. The following equipment was provided: a high shear mixerequipped with a Cowles Blade, and a low shear (Hobart) mixer. ENCOR 626(100% acrylic latex) was obtained from Arkema Coating Resins. The ENCOR626 latex binder has a particle size of 0.20 microns, a minimum filmforming temperature of 20° C., and a glass transition temperature of 29°C. K-20 Glass bubbles were obtained from 3M Company. W210 CeramicMicrospheres were obtained from 3M Company. POLYPHASE P20T and MERGAL192 biocides were obtained from Troy Corporation. Propylene glycol butylether (CAS Number 5131-66-8) was obtained from Sigma-Aldrich, St. Louis,Mo., under the product number 484415 (and is believed to besubstantially equivalent to the product obtainable from Dow Chemicalunder the trade designation DOWANOL PnB).

The ENCOR 626 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The POLYPHASE P20T, MERGAL 192, and propyleneglycol butyl ether were then added sequentially, while stirring on lowspeed. Following this, the W210 ceramic microspheres were slowly addedwith the mixer initially set on low speed. As the viscosity of themixture built upon addition of the ceramic microspheres, the mixer speedwas increased. After addition was complete, mixing of this pre-mix wascontinued for approximately 5 minutes. The premix was then used withoutdelay in the following step: The glass bubble filler was added to themixing bowl of the low shear mixer. The premix was then added to themixer by aid of a rubber spatula and the mixer was covered with aplastic or aluminum film to contain the very low density glass bubblesthat tend to be stirred out of the bowl without a physical means tocontain them. After providing this containment, the mixer was started onlow speed very briefly multiple times until virtually all the glassbubbles were wet with the premix mixture. At that point the plastic oraluminum film could be removed from the bowl. At this point the mixerspeed was increased to medium for approximately two minutes, then tohigh for approximately one minute. The mixer was then stopped and thebatch was inspected. Water was added as needed to provide the desiredconsistency of the product. A skilled operator can determine the amountof water to add while mixing at high speed by auscultation; if theviscosity is the correct range, the mixture will make a distinctive lowpitched sound as air begins to be entrained in the mixture. The mixturewas then transferred to a plastic bucket with a lid, for storage.

All components listed in Table 8 for Comparative Example 1 are in weightpercent, of the wall repair compound as formulated. (ENCOR 626 is anaqueous emulsion comprising 50 percent total solids). The batch size wasapproximately 1.7 kg.

TABLE 8 Component Weight Percent ENCOR 626 Binder Emulsion 56.07 K-20Glass Bubbles 25.38 Ceramic Microspheres 15.60 Propylene Glycol ButylEther 0.24 POLYPHASE P20T 0.41 MERGAL 192 0.11 Water to adjust 2.19

Comparative Example C2

A batch of wall repair compound was synthesized by the following generalmethods. The following equipment was provided: a high shear mixerequipped with a Cowles Blade, and a low shear (Hobart) mixer. CELVOLIT1774, (binder emulsion) was obtained from Celanese Emulsions. CELVOLIT1774 is a vinyl acetate/ethylene (VAE) emulsion having a particle sizeof 0.20 microns, a minimum film forming temperature of 0° C., and aglass transition temperature of 12° C. K-20 Glass bubbles were obtainedfrom 3M Company. W210 Ceramic Microspheres were obtained from 3MCompany. Titanium dioxide (TI-PURE R700), was obtained from DuPontChemicals, Wilmington, Del. POLYPHASE P20T and MERGAL 192 biocides wereobtained from Troy Corporation. Propylene glycol butyl ether (CAS Number5131-66-8) was obtained from Sigma-Aldrich, St. Louis, Mo., under theproduct number 484415 (and is believed to be substantially equivalent tothe product obtainable from Dow Chemical under the trade designationDOWANOL PnB).

The CELVOLIT 1774 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The POLYPHASE P20T, MERGAL 192, and propyleneglycol butyl ether were then added sequentially, while stirring on lowspeed. Following this, the W210 ceramic microspheres were slowly addedwith the mixer initially set on low speed. As the viscosity of themixture built upon addition of the ceramic microspheres, the mixer speedwas increased. The subsequent addition of the titanium dioxide likewiserequired additional mixer speed adjustment. After addition was complete,mixing of this pre-mix was continued for approximately 5 minutes. Thepremix was then used without delay in the following step: The glassbubble filler was added to the mixing bowl of the low shear mixer. Thepremix was then added to the mixer by aid of a rubber spatula and themixer was covered with a plastic or aluminum film to contain the verylow density glass bubbles that tend to be stirred out of the bowlwithout a physical means to contain them. After providing thiscontainment, the mixer was started on low speed very briefly multipletimes until virtually all the glass bubbles were wet with the premixmixture. At that point the plastic or aluminum film could be removedfrom the bowl. The mixer speed was increased to medium for approximatelytwo minutes, then to high for approximately one minute. The mixer wasthen stopped and the batch was inspected. Water was added as needed toprovide the desired consistency of the product. A skilled operator candetermine the amount of water to add while mixing at high speed byauscultation; if the viscosity is the correct range, the mixture willmake a distinctive low pitched sound as air begins to be entrained inthe mixture. The mixture was then transferred to a plastic bucket with alid, for storage.

All components listed in Table 9 for Comparative Example 2 are in weightpercent, of the wall repair compound as formulated. (CELVOLIT 1774 is anaqueous emulsion comprising 55 percent total solids). The batch size wasapproximately 0.5 kg.

TABLE 9 Component Weight Percent CELVOLIT 1774 Binder 46.34 EmulsionK-20 Glass Bubbles 20.98 Ceramic Microspheres 7.63 Titanium Dioxide11.44 Propylene Glycol Butyl Ether 0.20 POLYPHASE P20T 0.34 MERGAL 1920.09 Water to adjust 12.97

Comparative Example C3

A batch of wall repair compound was synthesized by the following generalmethods. The following equipment was provided: a high shear mixerequipped with a Cowles Blade, and a low shear (Hobart) mixer. RESYN7480, (binder emulsion) was obtained from Celanese Emulsions. RESYN 7480is a high molecular weight vinyl acrylic emulsion (vinylacetate/acrylate) having a particle size of 0.275 microns, a minimumfilm forming temperature of 8° C., and a glass transition temperature of18° C. K-20 Glass bubbles were obtained from 3M Company. W210 CeramicMicrospheres were obtained from 3M Company. Titanium dioxide (TI-PURER700), was obtained from DuPont Chemicals, Wilmington, Del. POLYPHASEP20T and MERGAL 192 biocides were obtained from Troy Corporation.Propylene glycol butyl ether (CAS Number 5131-66-8) was obtained fromSigma-Aldrich, St. Louis, Mo., under the product number 484415 (and isbelieved to be substantially equivalent to the product obtainable fromDow Chemical under the trade designation DOWANOL PnB).

The RESYN 7480 aqueous binder emulsion was added to a suitable sizedbeaker that was being stirred with an overhead driven Cowles mixingblade set on low speed. The POLYPHASE P20T, MERGAL 192, and propyleneglycol butyl ether were then added sequentially, while stirring on lowspeed. Following this, the W210 ceramic microspheres were slowly addedwith the mixer initially set on low speed. As the viscosity of themixture built upon addition of the ceramic microspheres, the mixer speedwas increased. The subsequent addition of the titanium dioxide likewiserequired additional mixer speed adjustment. After addition was complete,mixing of this pre-mix was continued for approximately 5 minutes. Thepremix was then used without delay in the following step: The glassbubble filler was added to the mixing bowl of the low shear mixer. Thepremix was then added to the mixer by aid of a rubber spatula and themixer was covered with a plastic or aluminum film to contain the verylow density glass bubbles that tend to be stirred out of the bowlwithout a physical means to contain them. After providing thiscontainment, the mixer was started on low speed very briefly multipletimes until virtually all the glass bubbles were wet with the premixmixture. At that point the plastic or aluminum film could be removedfrom the bowl. The mixer speed was increased to medium for approximatelytwo minutes, then to high for approximately one minute. The mixer wasthen stopped and the batch was inspected. Water was added as needed toprovide the desired consistency of the product. A skilled operator candetermine the amount of water to add while mixing at high speed byauscultation; if the viscosity is the correct range, the mixture willmake a distinctive low pitched sound as air begins to be entrained inthe mixture. The mixture was then transferred to a plastic bucket with alid, for storage.

All components listed in Table 10 for Comparative Example 3 are inweight percent, of the wall repair compound as formulated. (RESYN 7480is an aqueous emulsion comprising 55 percent total solids). The batchsize was approximately 0.5 kg.

TABLE 10 Component Weight Percent RESYN 7480 Binder Emulsion 46.09 K-20Glass Bubbles 20.86 Ceramic Microspheres 7.59 Titanium Dioxide 11.38Propylene Glycol Butyl Ether 0.20 POLYPHASE P20T 0.34 MERGAL 192 0.09Water to adjust 13.47

The Examples and Comparative Example spackle compounds were tested forHardness, Gloss Retention, Paint Anchorage, and Hiding Power Comparison,as described in the above test methods. Results are reported in Tables11-14.

TABLE 11 Shore OO Hardness - Shore OO Hardness - Second reading ExampleInitial Reading (after 60 Sec) 1 96 91 2 95 91 3 96 90 4 95 89 5 96 93 696 93 7 97 93 C1 98 97 C2 92 89 C3 93 93

TABLE 12 Example 85 Deg Gloss Reading Gloss Retention Index Control 1(painted, 5.5 NA primed drywall board 1 3.5 .64 Control 2 (painted, 10.2NA primed drywall board 2 4.1 .40 3 6.1 .60 4 3.8 .37 Control 3(painted, 11.5 NA primed drywall board 5 6.0 .52 6 5.9 .51 7 6.6 .57 Cl1.6 .29 C2 0.9 .16 C3 1.5 .27 Note: Control 1 was used to calculate theGloss Retention Index value for Examples 1 and C1-C3. Control 2 was usedto calculate the Gloss Retention Index values for Examples 2-4. Control3 was used to calculate the Gloss Retention Index values for Examples5-7.

TABLE 13 Example Paint Anchorage (Pass/Fail) 1 Pass 2 Pass 3 Pass 4 Pass5 Pass 6 Pass 7 Pass C1 Pass C2 Fail C3 Fail

TABLE 14 Example Hiding Power Comparison (Pass/Fail) 1 Pass 2 Fail 3Fail 4 Pass 5 Pass 6 Pass 7 Pass C1 Fail C2 Pass C3 Pass

Persons of ordinary skill in the art may appreciate that various changesand modifications may be made to the invention described above withoutdeviating from the inventive concept. Thus, the scope of the presentinvention should not be limited to the structures described in thisapplication, but only by the structures described by the language of theclaims and the equivalents of those structures.

What is claimed is:
 1. A spackling compound, comprising: (a) betweenabout 35% by weight and about 65% by weight acrylic latex resin; (b)between about 20% by weight and about 50% by weight filler material; and(c) between about 1% by weight and about 20% by weight water; whereinthe acrylic latex resin has an average latex particle size of less thanabout 0.18 microns.
 2. A spackling compound as defined in claim 1,wherein the resin has a minimum film formation temperature of less thanabout 15 degrees Celsius.
 3. A spackling compound as defined in claim 1,wherein the resin has a glass transition temperature (Tg) of less thanabout 25 degrees Celsius.
 4. A spackling compound as defined in claim 1,further comprising at least one colorant.
 5. A spackling compound asdefined in claim 4, wherein the dried spackling compound passes the 6mil hide test set forth in the specification.
 6. A spackling compound asdefined in claim 5, wherein the spackling compound comprises betweenabout 2% by weight and about 20% by weight colorant.
 7. A spacklingcompound as defined in claim 6, wherein the colorant comprises titaniumdioxide.
 8. A spackling compound as defined in claim 7, wherein thecolorant further comprises carbon black.
 9. A spackling compound asdefined in claim 8, wherein the carbon black comprises less than about0.02 percent by weight of the spackling compound.
 10. A spacklingcompound as defined in claim 1, wherein the spackling compound furthercomprises a coalescing aid.
 11. A spackling compound as defined in claim1, wherein the coalescing aid comprises trimethylpentanediolmonoisobutyrate.
 12. A spackling compound as defined in claim 1, whereinthe coalescing aid comprises less than about 1% by weight propyleneglycol.
 13. A spackling compound as defined in claim 1, wherein thespackling compound further comprises a dispersing agent.
 14. A spacklingcompound as defined in claim 1, wherein the dispersing agent comprisesless than about 1 percent by weight of a sodium salt of polymericcarboxylic acid.
 15. A spackling compound as defined in claim 1, whereinthe spackling compound further comprises a lubricant.
 16. A spacklingcompound as defined in claim 1, wherein the lubricant comprises lessthan about 1% by weight hydroxy ethyl cellulose.
 17. A spacklingcompound as defined in claim 1, wherein the filler comprises a bimodaldistribution of particles.
 18. A spackling compound as defined in claim1, wherein the bimodal distribution of particles comprises at least oneof glass bubbles and ceramic microspheres.
 19. A spackling compound asdefined in claim 1, wherein the filler is substantially free of minedorganic filler materials.
 20. A spackling compound as defined in claim1, wherein the dried spackling compound has an average 85 degree glossretention index of at least about 0.3 when testing according to themethod set forth in the specification.
 21. A spackling compound,comprising: (a) between about 45% by weight and about 60% by weightacrylic latex resin; (b) between about 25% by weight and about 45% byweight filler material; (c) between about 5% by weight and about 15% byweight titanium dioxide; and (d) between about 1% by weight and about15% by weight water; wherein the latex resin has an average latexparticle size of less than about 0.18 microns, a minimum film formationtemperature of less than about 15 degrees Celsius, and a glasstransition temperature (Tg) of less than about 25 degrees Celsius.
 22. Aspackling compound as defined in claim 21, wherein the dried spacklingcompound passes the 6 mil hide test defined in the specification, andfurther wherein the dried spackling compound has an average 85 degreegloss retention index of at least about 0.4 when testing according tothe method set forth in the specification.